SN

FTS 400/800-4Approach Lighting Systems

Reference Manual P/N #7914008004

Flash Technology, 332 Nichol Mill Lane, Franklin TN 37067(615) 261-2000

Front Matter

Abstract

This manual contains information and instructions for installing, operating, and maintaining the FTS 400 and 800 Approach Lighting Systems

manufactured by Flash Technology®, a Dielectric Company.

Copyright

Copyright © 1997-2003 Flash Technology®, Franklin, TN, 37067, U.S.A.

All rights reserved. Reproduction or use of any portion of this manual is prohibited without express written permission from Flash Technologyand/or its licenser.

Trademark Acknowledgments

Flash Technology® is a registered trademark name.

ElectroFlash™, Flash Tech™, Flash Technology™, FTCA™, Flash™ and the Flash Technology Logo are all trademarks of Flash Technology.

All trademarks and product names mentioned are properties of their respective companies, and are recognized and acknowledged as such by FlashTechnology.

Applicable Specification

This equipment meets or exceeds requirements for an FAA Type L-849 Styles A, C, and E, and Type L-859, Styles B, D, and F.

Disclaimer

While every effort has been made to ensure that the information in this manual is complete, accurate and up-to-date, Flash Technology assumesno liability for damages resulting from any errors or omissions in this manual, or from the use of the information contained herein. Flash Technol-ogy reserves the right to revise this manual without obligation to notify any person or organization of the revision.

In no event will Flash Technology be liable for direct, indirect, special, incidental, or consequential damages arising out of the use of or the inabil-ity to use this manual.

Warranty

Flash Technology warrants all components, under normal operating conditions, for two years.

Replacement Parts

The use of parts not manufactured or supplied by Flash Technology or unauthorized modification of this equipment voids the warranty andcould invalidate the assurance of complying with FAA requirements for Type L-849 Style A and E lights as published in Advisory Circular150/5345-51.

Pub. No. 0594-400/800-0009

ii Revision 1 — 12-11-2003 FTS 400/800-4

PERSONNEL HAZARD WARNING

Dangerous Voltages

Dangerous line voltages reside in certain locations in this equipment. Also, this equipment may generate dangerous voltages. Although FTCA has incorporated every practical safety precaution, exercise extreme caution at all times when you expose circuits and components, and when you operate, maintain, or service this equipment.

Avoid Touching Live CircuitsAvoid touching any component or any part of the circuitry while the equipment is operating. Do not change components or make adjustments inside the equipment with power on.

Dangerous Voltages Can Persist with Power DisconnectedUnder certain conditions, dangerous voltages can be present because capacitors can retain charges even after the power has been disconnected. Protect yourself — always turn off the input (primary) power and wait for one minute for storage capacitors to drain their charge. Then check between the red and blue wires on the TB2 terminal block with a voltmeter for any residual charge before touching any circuit element or component.

Do Not Depend on InterlocksNever depend on interlocks alone to remove unsafe voltages. Always check cir-cuits with a voltmeter. Under no circumstances remove or alter any safety inter-lock switch.

FTS 400/800-4 Revision 1 — 12-11-2003 iii

Table of Contents

Front Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiAbstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiCopyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiTrademark Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiApplicable Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiDisclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiWarranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiReplacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiSection 1 — Introduction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Elapsed Time Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Flash Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2FTC 435 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Setting Up the FTC 435 Series Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Note the following abbreviations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Style 1 Current Regulator — Three Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Style 1 Current Regulator — Two Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Style 2 Current Regulator — Three Intensity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Section 2 — Outline, Mounting, and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Power Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1FH 400 Flashhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1FH 800 Flashhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Outline and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Section 3 — Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Diagnostic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Control Signal Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1RFI Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Control Line Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Power Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Master Unit Checkout P/N 2652318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Slave Unit Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Master Unit Checkout P/N 2904413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Slave Unit Checkout P/N 2904413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

iv Revision 1- 12-11-2003 FTS 400/800-4

System Level Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Individual Light Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Capacitors (C1, C2, C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Flashtube (FT101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Relays (K1, K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10High Voltage Rectifier Board(PCB2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10High Voltage Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Trigger Coupling Transformer (T3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Timing and Trigger Board (PCB1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Bleed Resistor (R1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Interlock Switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Component Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11High Voltage Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Trigger Coupling Transformer (T3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Timing and Trigger Board (PCB1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11HV Rectifier Board (PCB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Section 4 — Replaceable & Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Power Converter Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Internal Controller Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Series Controller Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Flashhead Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Repackaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Section 5 — Programming T&T Board P/N 2904413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Connecting the Handheld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Using the Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

INFO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3MODE CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

INDEX I-1

FTS 400/800-4 Revision 1 — 12-11-2003 v

List of Figures

FTC 415 Internal Controller - Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3FTC 435 Series Controller - Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4FTC 435 Series Controller - Current Sense Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4Typical REIL Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4Typical ALS Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5PC 400-2 or PC 800-2 Power Converter Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6FH 400 Flashhead Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7FH 800 Flashhead Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8FTC 435 Series Controller Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9PC 400 and FH 400 Comounted Unit Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10PC 800 and FH 800 Comounted Unit Mounting and Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11Typical Wiring for FTS 410 or FTS 810 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12Typical Wiring for FTS 410 or FTS 810 with FTC 435 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13FH 400 or FH 800 Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14PC 400 & PC 800 Power Converter Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15FTC 415 Controller Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16FTC 435 Series Controller Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17PCB1 Timing and Trigger Board Pictorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8PCB1 Timming and Trigger Board P/N 2904413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9PC 400 and PC 800 Power Converter Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3FTC 415 Controller Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4FTC 435 Series Controller Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5FH 400 Flashhead Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7FH 800 Flashhead Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8FIGURE 5-1 Handheld Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

vi Revision 1 — 12-11-2003 FTS 400/800-4

List of Tables

FTC 415 Internal Controller—Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3System-Level Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Lighting Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7High Voltage Transformer (T1) Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Power Converter Major Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2FTC 415 Controller Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4FTC 435 Controller Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5FH 400 and FH 800 Flashhead Major Replaceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

FTS 400/800-4 Revision 1 — 12-11-2003 vii

Section 1 — Introduction and Operation

System

FTS 400 System: An FTS 400 Approach Lighting Sys-tem consists of two or more lighting units. Each lighting unit is composed of an FH 400 Flashhead and PC 400 Power Converter. The power converter in the system is a PC 410 with an FTC 415 Internal Controller. Power con-verters without controllers are slaves known as PC 400-2 Power Converters.

FTS 800 System: An FTS 800 Approach Lighting Sys-tem consists of two or more lighting units. Each lighting unit is composed of an FH 800 Flashhead and PC 800 Power Converter. The power converter in the system is a PC 810 with an FTC 415 Internal Controller . Power con-verters without controllers are slaves known as PC 800-2 Power Converters.

The FH 400 Flashhead produces a beam covering 360 degrees horizontally and 8 degrees, or more, vertically. The lens directs the main part of the beam upward toward the airways, while limiting stray light toward the ground.

The FH 800 Flashhead directs the beam 30 degrees hori-zontally and 10 degrees vertically. The flashhead is attached to a two-inch threaded pipe by a yoke that has provisions for horizontal and vertical aiming and locking.

In ALS applications, the lights are aligned with the center line of the runway and flash sequentially toward the land-ing threshold. An ALS installation may have from 3 to 21 (or more) sequentially flashing lights.

A REIL (Runway End Identifier Lights) system consists of only two lights that are located on each side of the run-way at the landing threshold. The REIL lights flash (simultaneously) after the last center line light has flashed.

The lights can be used in a combined ALS and REIL con-figuration.

Specifications

Physical :Heights include dimensions of the units only and do not include the distance from the bottom of each unit to the ground.

FTS 400 Comounted Assembly:(H x W x D) 29 x 25 x 14 in., 25 lbs.

724 x 635 x 356 mm, 11.5 kg.FTS 800 Comounted Assembly:

(H x W x D) 25 x 25 x 14 in., 25 lbs.622 x 635 x 356 mm, 11.53 kg.

PC 400-2 or PC 800-2 Power Converter:(H x W x D) 12.3 x 19.5 x 13.5 in., 21 lbs.

311 x 494 x 341 mm, 9.53 kg.FH 400 Flashhead:

(H x W x D) 16.5 x 13.5 x 13.5 in., 10 lbs.419 x 343 x 343 mm., 4.5 kg.

FH 800 Flashhead:(H x W x D) 10.8 x 7.80 in., 4 lbs.

226 x 198 mm, 1.82 kg.

Performance Character ist ics:

P o w e r R e q u i r e m e n t s :Voltage and Frequency 120 VAC, 60 HzVolt-Amperes 300 VA peakFTS 400 Power Req. 105 W high int.

65 W medium int.50 W low int.

FTS 800 Power Req. 120 fps 190 W high int.75 W medium int.

55 W low int.60 fps 135 W high int.

65 W medium int.50 W low int.

FTS 400/800-4 Revision 1 — 12-11-2003 1-1

F l a s h I n t e n s i t y :FTS 400:

High Intensity 5,000 cdMedium Intensity 1,500 cdLow Intensity 300 cd

FTS 800:High Intensity 15,000 cdMedium Intensity 1500 cdLow Intensity 300 cd

F l a s h R a t e :FTS 400 60 flashes per minuteFTS 800 120 flashes per minute

F l a s h C o v e r a g e :FH 400:

Horizontal 360 degreesVertical 8 degrees (minimum)

FH 800:Horizontal 30 degrees (minimum)Vertical 10 degrees (minimum)

A p p l i c a t i o n : L - 8 4 9R a d i o I n t e r f a c e : L - 8 5 4C o n t r o l I n t e r f a c e :

FTC 415 Internal Controller

C o n t r o l Ty p e :Master/slave with common referencetiming.

M o n i t o r i n g & E n v i r o n m e n t a l :Complies with FAA AdvisoryCircularAC 150/5345-51.

Elapsed Time Meter

The Elapased Time Meter shows the hours of operation at high intensity. You can use this timer, for example, to schedule inspections, cleaning, or flashtube replacement as preventive maintenance.

Flash Monitor

The Flash Monitor allows monitoring flash operation with external monitoring equipment. The main terminal block TB1 has two connections at TB1-4 and TB1-5 to which you can connect the monitoring device. These con-tacts open upon failure of the flashtube for more than approximately 12 seconds. When you first turn the unit on, a failure may be indicated for about 12 seconds until the montior detects sufficient flashes to close the contacts. After this initial period, the contacts remain closed until a failure occurs or the power is removed.

FTC 435 Controller

The FTC 435 is a series-fed current-operated external controller for the master lighting unit. A switch on its front panel controls low, medium, and high light intensity, or allows control from current steps in a constant current regulator.

OperationElectroFlash ODALS and REIL systems uses an FTC 415 Internal Controller, which is combined with one of the power converters.

Each lighting unit (power converter) has internal timing circuitry to fix the instant at which it flashes. This signal also contains encoded flash intensity information. A con-trol line, which enables sequential flashing, interconnects all the lights.

Controls and Indicators

Table 1-1 describes controls for the FTC 415 Internal Controller, and Figure 1-1 shows these controls.

1-2 Revision 1 — 12-11-2003 FTS 400/800-4

81000031

Figure 1-1 FTC 415 Internal Controller - Controls and Indicators

Table 1-1 FTC 415 Internal Controller—Controls

Item Description Function

1 Power Circuit Breaker Applies AC power to the lighting system.

2 Remote Control Fuse Protects the remote control AC line.

3 MODE Selector

Selects one of five operating modes:• REMOTE places the system in remote control mode, controlled at another location.• OFF removes power from the lighting units.• LOW activates flashing at low intensity.• MED activates flashing at medium intensity.• HIGH activates flashing at high intensity.

REMOTE

TB

201OFF OFF

POWER21 3 4 5 6 CTRL HI

MED

HIGH

3-7355-01G

LOW

FTC 415

REMOTE

FUSELOM N

MODE

OFF

CTRL VAC OUTFOR REMOTE SWITCH

CTRL VAC RETURNFROM REMOTESWITCH

1 2 3

FTS 400/800-4 Revision 1 — 12-11-2003 1-3

Setting Up the FTC 435 Series ControllerFor the following procedures, refer to Figure 1-2 and Fig-ure 1-3.

81000033

Figure 1-2 FTC 435 Series Controller - Con-trols

81000034

Figure 1-3 FTC 435 Series Controller - Cur-rent Sense Board

Note the following abbreviations:

• CCR (Constant Current Regulator)

• CCW (Counterclockwise)

• CW (Clockwise)

• LED (Light Emitting Diode)

The FTC 435 Series Controller can be set up for three-intensity operation using a Constant Current Regu-lator Type L-828, Class 1 (6.6 amps.): Style 1 (Three Step); Style 1 (Two Step); or Style 2 (Five Step). To set up the FTC 435 Series Controller, use the following pro-cedure:

Style 1 Current Regulator — Three Intensity Lev-els

For this style, the lighting system switches off only when the CCR is switched off.

1. Turn the SENSE control fully CCW.2. Turn the HIGH, MED, and LOW controls fully CW.3. Set the CCR to STEP 1 and adjust the LOW pot

CCW until LOW LED just comes on.4. Set the CCR to STEP 2 and adjust MED pot CCW

until the MED LED just comes on.5. Set the CCR to Step 3 and adjust the HIGH pot CCW

until the HIGH LED just comes on.6. Recheck the light at all current steps and verify that

LEDs respond correctly at each step. Also verify by visual comparison that flashing intensity decreases when the CCR is switched from Step 3 to Step 2, and that it decreases further when the CCR is switched from Step 2 to Step 1.

Style 1 Current Regulator — Two Intensity Lev-els

For this style, the lighting system switches off when the CCR is at Step 1. It flashes at LOW intensity when the CCR is at Step 2, and at HIGH intensity when the CCR is at Step 3.

FTC 435

IN OU

T

GN

D

1 2 3 1 2 3 4

TB1TB2

CO

NT

RO

LV

OLT

AG

E

LOW

ME

D

HIG

HINTENSITY CONTROL

AUTOLOW

MEDHIGH

RUNWAYLOOP

SERIESCURRENT

1 2 3 4 5 6 7 8 9 10 11

SENSER51

SYNC

LOW

MED

HIGH

R21

R22

R23

1-4 Revision 1 — 12-11-2003 FTS 400/800-4

1. Turn the SENSE control fully CCW.

2. Turn the HIGH, MED, and LOW control fully CW.

3. Set the CCR to Step 2 and adjust the LOW control CCW until the LOW LED just comes on and the strobe light flashes in low intensity.

4. Set the CCR to Step 3 and adjust the HIGH control CCW until the HIGH LED just comes on.

5. Recheck the light at all current steps and verify that LEDs respond correctly at each step. Also verify by visual comparison that flashing intensity decreases when the CCR is switched from Step 3 to Step 2, and that the light switches off completely when the CCR is switched from Step 2 to Step 1.

Style 2 Current Regulator — Three Intensity Lev-els

For this style, the lighting system switches on when the CCR is at Step 1 and switches to progressively higher intensities as you switch the CCR to higher steps.

1. Turn the SENSE control fully CCW.2. Turn the HIGH, MED, and LOW controls fully CW.3. Set the CCR to Step 1 and adjust the LOW control

CCW until the LOW LED just comes on.4. Set the CCR to Step 3 and adjust the MED control

CCW until the MED LED just comes on.5. Set the CCR to Step 5 and adjust the HIGH control

CCW until the HIGH LED just comes on.6. Set the CCR to Step 4 and verify that the HIGH LED

goes off. If not, you may need to adjust the HIGH control slightly CW until it does.

7. Set the CCR to Step 2 and verify the MED LED goes off.

8. Recheck the light at all current steps and verify that LEDs respond correctly at each step. Make trimming adjustments if necessary. Also verify by visual com-parison that flashing intensity decreases when the CCR is switched from Step 5 to Step 4, and that it decreases further when the CCR is switched to Step 2.

FTS 400/800-4 Revision 1 — 12-11-2003 1-5

This page is intentionally blank.

1-6 Revision 1 — 12-11-2003 FTS 400/800-4

Section 2 — Outline, Mounting, and Installation

Unpacking

Inspect shipping cartons for signs of damage. Check package contents against the packing list and inspect each item for visible damage. Damage claims should be reported promptly to the freight handler.

ATTENTIONEach light is packaged in its own ship-ping carton. The position at which thelight is to be installed is marked on thecarton and on an ID label on the outsideof the power converter. Refer to Figure2-1 and Figure 2-2 to identify positions.

Tools

The following hand tools are suggested for installation and maintenance:

• Phillips®-head screwdriver, #2

• 9- or 12-inch (# 2 - 3⁄16"), flat-blade screwdriver

• 9- or 12-inch (# 3 - 5⁄16"), flat-blade screwdriver

• Medium, slip joint pliers

• Set of combination wrenches

• 8-in. adjustable wrench

• Assorted nut-driver handles (1⁄4", 5⁄16", 3⁄8")

• Universal terminal crimper

• Spanner wrench for 2-inch conduit locking nut

• Triplett™ Model 630-NA VOM, or equivalent analog volt-ohm meter

Access

WARNINGRead the warning on Page iii. Discon-nect primary power before openingenclosures.

Power Converter

The power converter enclosure consists of a thermoplas-tic cover attached to an aluminum base. Wing-handled latches secure the cover. The cover tilts open for access to the interior.

FH 400 Flashhead

Three screw-fastened plates secure the lens to its base. Remove these to access the interior of the flashhead.

FH 800 Flashhead

Three screws fasten the bezel, which holds the flashtube in place. Remove these to access the flashtube or the inte-rior.

Outline and MountingEach lighting unit consists of a power converter and a flashhead, mounted as separate units or comounted as a single unit. Frangible mounting couplings are available from FTCA. Use the outline and mounting dimensions shown in Figures 2-3 to 2-8.

Separately Mounted Power Converter: Mounting and outline is shown in Figure 2-3. The base plate has mounting holes for two 2-inch threaded pipes.

Separately Mounted Flashhead: Mounting and out-line is shown in Figure 2-4 and Figure 2-5. Separately mounted, the flashhead is typically installed on a pedestal or tower.

Comounted Assembly: Figure 2-7 shows a comounted assembly, a common configuration for REIL applications. Mounting pipe details are similar to those in Figure 2-3, except that you must consider the increased overall height.

Installation

This manual may not contain all the information about installation wiring for your installation.

FTS 400/800-4 Revision 1 — 12-11-2003 2-1

NOTEIf installation drawings prepared spe-cifically for your site disagree withinformation provided in this manual,the site installation drawings shouldtake precedence. Consult anysite-specific installation wiring dia-gram supplied with your equipment.

FTCA wiring diagrams define only minimum require-ments recommended for satisfactory equipment opera-tion. It is the responsibility of the installer to comply with all applicable electrical codes.

Conduit and other distribution wiring details can be found on electrical installation diagrams provided by FTCA or others.

Figure 2-1 Typical REIL Configurations illustrates a typ-ical REIL configuration. For the FTS 410, the two lights are functionally and physically interchangeable. The mas-ter light is designated as A, Although these lights flash simultaneously, lights for positions A and B should not be interchanged unless each one is re-aimed. The factory presents aiming for the position. Flashheads are typically comounted with power converters for REIL applications.

Figure 2-2 Typical ALS Configurations shows lights a typical RAILs. The five RAILs are labeled from 1 to 5 to identify their positions; the light with the lowest number is located farthest from the runway and is the first to flash. RAILs are typically configured by mounting power converters and flashheads as separate units. The two REILs are labeled A and B, with the master light as A.

Wiring

System power is supplied to the system controller. A con-tactor in the controller uses two conductors to distribute power to all power converters in the system. Wire nuts connect line power wires to the controllers, and include those from the controllers to the power converters. These wires are connected at the power converter fuse terminals with screw connections. Typically, the wires are run through conduits and junction boxes and installed by electricians. Figure 2-9 provides wiring guidelines for systems with internal controllers, while Figure provides guidelines for systems with external controllers. These figures are for reference only and may not exactly agree with details in your installation. Always follow instruc-

tions in the Site Installation Diagram supplied with your equipment.

CAUTIONThis equipment is power phase sensi-tive. L1 and L2 must be wired to F1 andF2 in a consistent manner throughoutthe entire lighting system.

Note that the wiring diagrams define minimum require-ments and may not comply with all applicable electrical codes. It is the responsibility of the end user to comply with all prevailing electrical codes.

Determine the wire gauge for power lines by considering service voltage, length of the wire run, and total load (number of lighting units). Use a value of 300 VA per lighting unit and do not permit the voltage drop caused by wire resistance to exceed 5% at any light. Internal or external control units add less than 25W to the total load. Also, use the value of 300 VA to determine the circuit breaker or the slow-acting fuse rating at the service dis-connect box.

Wire control lines from the master power converter to all remaining power converters in the system by using two unshielded #14 AWG (or larger) conductors, twisted together (6 turns per foot is recommended). NOTE: FTCA recommends 600 Volt insulation on all wires that interconnect the lighting system. FTCA recommends a counterpoise consisting of bare solid copper.

When you mount flashheads separately from power con-verters, wire each respective flashhead to TB2 in its cor-responding power converter by using a five-conductor cable (typically FTCA PN 6340).

Ground all power converter and separately- mounted flashhead cases to the site grounding system. FTCA pro-vides a grounding lug on each power converter base. FTCA does not recommend connecting to the counter-poise for lightning protection.

Installation Checklist

Complete the following steps before applying power:

1. Inspect all equipment for damage.

2. Verify the received equipment against the packing list to ensure completeness.

2-2 Revision 1 — 12-11-2003 FTS 400/800-4

3. Power Converter Mounting:Position and mount each unit allowing adequate clearance for opening the covers. Also, use the fol-lowing guidelines:

– Ensure that the case is mounted upright.

– Check hardware inside the case to ensure that the chassis mounting screws and nuts are tight.

– Ensure that the bottom of the case has clear drain holes.

– Ensure that no holes are punched or drilled on the top surface of the case.

– Ensure that air can flow around the case.

– Mount the power converter away from radio frequency interference (RFI).

4. Power Converter Wiring:Examine the installation drawings and use the follow-ing guidelines:

– Check for proper incoming service voltage and current.

– Wire each unit according to the instructions.

– Ensure that all power converters are on the same line phase.

– Check all electrical connections for tightness.

– Check all terminal strip connections for tight-ness.

– Ground the power converter to the site grounding system.

5. Flashhead Mounting:

– Check the aim of the flashhead.

6. Flashhead Wiring:

– Ground the flashhead if not comounted.

– Check the wiring of the flashhead cable to the flashhead.

After completing all the steps listed above, turn on the power and perform an operational checkout from proce-dures in Section 3 of this manual.

FTS 400/800-4 Revision 1 — 12-11-2003 2-3

81000021

Figure 2-1 Typical REIL Configurations

LANDINGTHRESHOLD

A

PC 810FH800

MASTER UNIT CONTAININGFTC 415 INTERNAL CONTROLLER

BPC 800

FH800

B

FH400

THRESHOLDLANDING

FH400

PC400 410

PCA

CONFIGURATION WITHINTERNAL CONTROLLER

FTS 400 SYSTEM

FTS 800 SYSTEM

OMNIDIRECTIONAL FLASHHEADS

UNIDIRECTIONAL FLASHHEADS

MASTER UNIT CONTAININGFTC 415 INTERNAL CONTROLLER

2-4 Revision 1 — 12-11-2003 FTS 400/800-4

81000022

Figure 2-2 Typical ALS Configurations

INTERNAL CONTROLLERCONTAINING FTC 415

MASTER U NIT

2

INTERNAL CONTROLLERCONFIGURATION WITH

PC1

PC

PC

PC

800PC

3

4

FH 800

FH 800

5

B 800PC

800FH

LAND INGTH RESHOLD

800FH

PC810 A

FTS 800 SYSTEM

800

800

800

800

FH 800

FH 800

FH 800

FTS 400 SYSTEM

PC400

FH 400

B

FH400

MASTER U NITCONTAINING FTC 415

INTERNAL CONTROLLER

PC400

PC400

PC400

PC400

FH 400

FH 400

FH 400

FH 400

1

2

3

4

5

TH RESHOLDLAND ING

FH400

PC400 410

PCA

CONFIGURATION WITHINTERNAL CONTROLLER

FTS 400/800-4 Revision 1 — 12-11-2003 2-5

81000023

Figure 2-3 PC 400-2 or PC 800-2 Power Converter Mounting and Outline

12.3(311)

13.5(341)

8.00(203)

19.5(494)

2" NPT PIPE(NOT SUPPLIED)

FRANGIBLECOUPLING

PAD

GROUND

2.25 (57.2)(NOMINAL)

2.38 DIA(60.5)

LEVEL

NOTE:DIMENSIONS ARE ININCHES (MILLIMETERS)

2-6 Revision 1 — 12-11-2003 FTS 400/800-4

81000025

Figure 2-4 FH 400 Flashhead Mounting and Outline

13.5 (343) DIA

LEVELING NUTS(3 PLACES)

2.38 (60.3) DIAMOUNTING HOLE

1.06 (27) DIA

3. DIMENSIONS ARE IN INCHES (MILLIMETERS).2. WIND AREA = 1 SQ.FT. (.09 SQ.M.)1. APPROXIMATE WEIGHT = 10 LBS. (4.54 KG.)

IN LEVELING PLATE

4. EXTRA HOLE IS USED WHEN FLASHHEAD

16.5 (419)

IS MOUNTED ON A FRANGIBLE MAST.

FTS 400/800-4 Revision 1 — 12-11-2003 2-7

81000026

Figure 2-5 FH 800 Flashhead Mounting and Outline

15°

10.8(273)

7.80(198)

(60.5)2.38 DIA

6.7(170)

8.9(226)

5.25(133)

2-8 Revision 1 — 12-11-2003 FTS 400/800-4

81000024

Figure 2-6 FTC 435 Series Controller Mounting and Outline

14.5 (367)

12.5 (318)

10.5 (267)

0.5 (13)0.88 (22)

0.31 (8)

Ø1.31 (Ø33.3)

Ø1.31 (Ø33.3)

5.00 (127)

2.50 (63.5)

10.9 (277)

R1.5 (R38.1)

NOTES:DIMENSIONS ARE IN INCHES (MILLIMETERS)WEIGHT=11 LBS. (5 KG.)

12.9 (329)

.16 (4)

15.6 (396)

6.41 (163)

NOTEDIMENSIONS AREIN INCHES (MILLIMETERS)

15.4 (392)

2.50 (63.5)

8.0 (203)

12.3 (311)

FTS 400/800-4 Revision 1 — 12-11-2003 2-9

81000027

Figure 2-7 PC 400 and FH 400 Comounted Unit Mounting and Outline

1.2 FLASHHEAD = 8 [3.6].

(203)

(508)

(356)14.0

8.00

20.0

LC

PAD

COUPLING

2" NPT PIPE (SUPPLIED BY OTHERS)

FRANGIBLE

(311)12.3

(724)28.5

LEVELING SCREWS(3 PLACES)

NOMINAL

GROUND LEVEL

2.25 (57.2)

DIMENSIONS ARE IN INCHES [MILLIMETERS].WEIGHTS ARE IN POUNDS [KILOGRAMS].

2.0

15.0(381)

NOTES:

1.0 WEIGHT

1.1 POWER CONVERTER = 21 [9.5].

2-10 Revision 1 — 12-11-2003 FTS 400/800-4

81000028

Figure 2-8 PC 800 and FH 800 Comounted Unit Mounting and Outline

24.5(622)

2.25 (57.2)NOMINAL

GROUNDLEVEL

2.38 DIA(60.5)

8.00(203)

20.0(508)

14.0(356)

2" NPT PIPE(NOT SUPPLIED)

FRANGIBLECOUPLING

PAD

DIMENSIONS AREIN INCHES (MILLIMETERS)

FTS 400/800-4 Revision 1 — 12-11-2003 2-11

81000029

Figure 2-9 Typical Wiring for FTS 410 or FTS 810 System

INP

UT

TO

TE

RM

INA

L 10

TO

TE

RM

INA

L 9

TO

TE

RM

INA

L 8

FT

C 4

15 T

B20

1

* O

PT

ION

AL:

EIT

HE

R C

TR

L V

AC

OR

OP

EN

VA

C

ME

DIU

M

INT

EN

SIT

Y R

EM

OT

E C

ON

TR

OL

CH

AR

T

*VA

C

*

HIG

H

VA

C

OP

EN

OP

EN

*

OP

EN

OP

EN

OP

EN

OP

EN

LOW

OF

F

REDBLUBLKWHTPUR

SHIELD

BLK

REDBLU

PURWHT

SHIELD

BLK

REDBLU

PURWHT

SHIELD

PC

400

/800

RT

N

BLU

NO

TES

4, 6

LINE 2

F2

F1

3

SH

IELD

WH

T

LINE 1

5

PU

R

43B

LK

CO

NT

RO

LTB

11 2

PC

400

/800

1 2

RE

D

RE

D

WH

T

SH

IELD

BLK

NO

TES

4, 6

F2

F1

LINE 1LINE 2

4 5

PU

R

CO

NT

RO

L

RT

N

PC

410

/810

TB

1

21 3

21 3B

LU

58

67

910

HM

LT

B20

1

LINE 1LINE 2

(AN

OD

E)

RE

D

(CA

TH)

BLU

(TR

IG)

BLK

(TR

IG R

TN

) W

HT

(GN

D) P

UR

TB

2

RTN

BLU

(TR

IG R

TN

) WH

T

NO

TE

S 4

, 6

LINE 1LINE 2

F2F1

3

(TR

IG) B

LK(C

AT

H)

BLU

(GN

D)

PU

R

5

PU

RS

HIE

LD

43

WH

TB

LK

1 2

TB

1C

ON

TR

OL

(AN

OD

E) R

ED

1 2

RE

DTB

2

H M L CT

RL

VA

C

TY

PIC

AL

RE

MO

TE

SW

ITC

HIN

G D

EV

ICE

FO

R E

XA

MP

LE,

L-85

4 R

AD

IOR

CV

R/C

ON

TR

OLL

ER

SE

E R

EM

OT

EC

ON

TR

OL

CH

AR

T

CO

UN

TE

RP

OIS

E (

NO

TE

3)

INP

UT

PO

WE

RFR

OM

SE

RV

ICE

DIS

CO

NN

EC

T

PO

WE

R T

O O

TH

ER

LIG

HT

SN

OT

ES

8, 9

& 1

0.C

ON

TRO

L W

IRE

S(T

WIS

TE

D, U

NS

HIE

LDE

D)

NO

TES

7, 8

& 9

.

CO

UN

TE

RP

OIS

E

CO

NT

RO

L

PO

WE

R

TO

OT

HE

RLI

GH

TSA

S R

EQ

DF

OR

OD

ALSAD

DIT

ION

AL

LIG

HT

S F

OR

OD

ALS

RE

IL P

AIR

PN

634

0 C

AB

LE(T

YP

ICA

L)

NO

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2-12 Revision 1 — 12-11-2003 FTS 400/800-4

810000211

Figure 2-10 Typical Wiring for FTS 410 or FTS 810 with FTC 435 Controller

P C 4 1 0 O R P C 8 1 0

C O U N T E R P O IS E

R E D

B LUB L KW H T

P U R

S H IE L D

G N D

T R IG R T NT R IG

C A T H

A N O D E 12345

T B 1123

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C O N T R O L

C O N N E C T E D A T F A C T O R Y

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F 1

K 20 3

W H T /R E D

W H T /B L K B LK

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C B 2 01

TB

201

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F T C 41 5 IN T ER N A L C O N T R O L L E R

LIN

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LIN

E 1

LIN

E 2

LIN

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LMHN

T OF L A S H H E A D

T O

O T H E R

L IG H T IN G

U N ITS

12 0 /24 0 V A C 6 0H ZF R O M S E R V IC ED IS C O N N E C TS W IT C H

L1

L 2 /N E U T

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S E R IE SC U R R E N TL IN E

FTS 400/800-4 Revision 1 — 12-11-2003 2-13

810000212

Figure 2-11 FH 400 or FH 800 Internal Wiring

FT101

RC101

T101TRIGGER

TRANSFORMER

FLASHTUBE

RE

D(A

NO

DE

) R

ED

(CA

TH

OD

E)

BLU

BLU

(TR

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ER

) B

LKB

LK

(TR

IGG

ER

RT

N.)

WH

TW

HT

(SH

IELD

& G

RO

UN

D)

PU

RP

UR

CONNECTIONS TOLIGHTING UNITS

2-14 Revision 1 — 12-11-2003 FTS 400/800-4

400800IW

Figure 2-12 PC 400 & PC 800 Power Converter Internal Wiring

K1

RE

LAY

HIG

H M

OD

E

2. J

UM

PE

R U

SE

D IN

SLA

VE

UN

ITS

ON

LY.

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LIN

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LIN

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BLUWHT/GRN

RED

WHT/GRN

BLK

WHT/BRN

WHT/VIO

WHT/BLU

WHT/ORN

4

PC

B1

TIM

ING

& T

RIG

GE

R

RE

D

BL

K

TRIGGER 110VAC

24VAC

24VAC

TB

33

21

CONTROL SIGNAL

GROUND

TRIGGER SIGNAL

LOW MODE RELAY

HIGH MODE RELAY

INTENSITY

76

511

109

8

TB

1

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6

WH

T/G

RN

WH

T/O

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HV 1

HV 3

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D

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SH

IELD

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R

FTS 400/800-4 Revision 1 — 12-11-2003 2-15

415-2IW

Figure 2-13 FTC 415 Controller Internal Wiring

3-7

355-

01G

R20

1

OFF

LIN

E 2

MA

Y B

E T

HE

NE

UT

RA

L F

RO

M S

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.

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2

NO

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R

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BLK

CB

1

CB

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ED

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D

BL

K

YE

L

BL

KME

DL

OW

OR

N

HI

7 1 2853 4

6

WH

TW

HT

RE

DR

EDW

HT

/RE

D

WH

T/B

LK

PO

WE

RK

203

WH

T/R

ED

WH

T/B

LK

GR

N

F20

1

RE

D

BLU

F2F1

CH

AS

SIS

GN

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TB

201

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VIO

BLU

21

24K

VI0

TB

1-5

VIO

3

UN

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HE

R L

IGH

TIN

GP

OW

ER

TO

BL

K

WH

TW

HT

OR

G

BL

K

BL

U

B A16 4

9 7

WH

TW

HT

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L

ME

DK

202

ABB

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BLKG

RY

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IGH

RE

D

GR

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WH

T

RE

D

CT

RL

7

NL

2

WHT

5

RED

43

BLU

6H

ML

L2/

N

ORN

YEL

98

WHT

RED

1110

RE

MO

TE

(CE

NT

ER

)(S

IDE

)

BR

N

VIO

GRN

YEL

VA

C

LIN

E

LIN

E

LO

AD

LO

AD

CB

201

L2

L1

GN

D

INT

CO

NN

EC

TIO

NS

TO

HO

ST

UN

IT

GN

D

(NO

TE

3)

WH

T/B

LK

WH

T/R

ED

TO

F2

TO

F1

3. IS

OL

AT

ED

CO

NT

AC

TS

RE

QU

IRE

D F

OR

RE

MO

TE

SW

ITC

HIN

G.

NE

UT

RA

L

WH

T/B

LK

WH

T/R

ED

2-16 Revision 1 — 12-11-2003 FTS 400/800-4

435IW

Figure 2-14 FTC 435 Series Controller Internal Wiring

3-7682-01REV E

POWERTRANSFORMER

4

3

T1

2

1

7 10 118 95 62 431

CURRENT SENSEPCB1

2

G1

GND

SERIESLOOP

CURRENT3

RUNAWAYTB1

1

7

8

9

RELAY BOARD

5

6

2

4

3

PCB2

1

TB2

3

4

1

2LOW

MED

HIGH

CTRL VOLTS

MEDAUTOLOW

HI

S1

RE

D

WHT/BRN

WHT/ORN

RED

ORN

VIO

RE

D

OR

N

VIO

WH

T/O

RN

BR

N

BL

U

BL

K

WH

T/R

ED

GRYGRYYELYEL

ORNORNREDRED

BRN

BLU

BLK

RED

ORN

GRY

YEL

GRY

YE

L

OR

N

INTENSITY CONTROL

J1

WHT/RED

FTS 400/800-4 Revision 1 — 12-11-2003 2-17

This page is intentionally blank.

2-18 Revision 1 — 12-11-2003 FTS 400/800-4

Section 3 — Maintenance and Troubleshooting

Safety

WARNINGBefore proceeding—read warning onPage iii.

Work safely, as follows:

1. Remove rings and watches before opening the equip-ment.

2. Shut off the equipment.

3. Remove the component or connect the test instru-ments.

4. Replace the component.

5. Turn on the power and test the system.

6. Turn off the power and disconnect the test equipment.

Preventive Maintenance

Carry out the following inspection and cleaning proce-dures at least once a year:

1. Verify that moisture has not accidentally entered the equipment through gaskets or seals, or collected inside as condensation.

2. Verify that all drain holes are clear.

3. Check terminal blocks and relays for evidence of cor-rosion and electrical arcing. Clean or replace any component that shows evidence of high-voltage dam-age.

4. Check flashtube connections for signs of pitting or arcing. Verify that anode and cathode connections are firmly tightened.

5. Check all electrical connections for tightness and ver-ify the absence of corrosion or electrical arcing.

6. Clean the outside surface of the FH 800 glass with liquid detergent and water. Wipe it gently with a soft cloth.

7. Clean the inside surface of the FH 400 lens with an FTCA-approved professional plastic cleaner. Wipe the lens with cheesecloth only. Do not use regular

cloth or paper towels. A lens cleaning kit, Part Num-ber 8630801, is available from FTCA. Contact Cus-tomer Service at 1-800-821-5825.

Storage

No special considerations are required for long-term stor-age of any major assembly, such as the power converter or flashhead, or any internal component. Circuit boards, when not installed in the equipment, should be kept in antistatic bags or containers.

Diagnostic Testing

You can benefit by observing the behavior of the system as a whole and each lighting unit in particular when carry-ing out these test procedures; the observations will be useful for troubleshooting.

NOTE

This equipment uses a method of mas-ter/slave control that enhances its oper-ation as a system. This type of controlcan sometimes cause misleading symp-toms if one of the lighting units malfunc-tions. Thus, it may be necessary todisconnect the interconnecting controlwire and to verify the operation of eachlighting unit independently to pinpointthe cause of a problem.

Control Signal Evaluation

Refer to Figure 2-1. Note that, for each power converter, a control line and its return line are connected to TB1-1 and TB1-3 respectively. The synchronization signal on this line is a pulse. Therefore, it is difficult to evaluate with a meter. Evaluating the control signal can be per-formed with a digital voltmeter that has an averaging function. Or, you can use an analog volt-ohmmeter such as the Triplett Model 630 set on the 3-volt scale. With either meter, the pulses that may be present on the line produce only momentary indications.

FTS 400/800-4 Revision 1 — 12-11-2003 3-1

However, to be aware of how your particular meter responds to these signals, use the following information to evaluate the response:

• The low-intensity pulse is approximately 16 ms in duration

• The medium-intensity pulse is 33 ms in duration

• The high-intensity pulse is 66 ms in duration

The longer pulse deflects the needle more than the shorter pulse on an analog meter, or the longer pulse reads higher than the shorter pulse on a digital meter with an averaging function. Observe these signals with your meter and record the meter readings for future reference.

For example, using the Triplett Model 630 set on the 3-volt scale (AC or DC), the high-intensity control pulse deflects the needle 70-80% of full scale, the medium-intensity control pulse deflects the needle 50%, and the low-intensity control pulse deflects the needle 20-30%. On an analog meter, the needle must return to zero between pulses. If it does not, signal interference may be occurring, as described next; or, you system may have RFI (radio frequency interference) problems as described in Section RFI Problems.

If the entire system flashes at the wrong intensity or exhibits any other abnormal flashing behavior affecting all the lighting units, a control signal problem is indi-cated. Although the problem could originate at the con-troller or at the master unit, it could also be caused by any of the slave units, because all lighting units communicate bidirectionally in this type of master/slave system. A problem of this type is isolated by disconnecting each lighting unit from the control wire and examining its behavior independently.

The following procedures describe how to isolate each control problem to a single lighting unit or to the control signal wire itself.

RFI Problems

The presence of radio frequency interference (RFI) can cause a light to flash intermittently, at the wrong rate, or at the wrong intensity. RFI can enter the light by any wire to or from the unit. For example:

• RFI on primary power wires could cause errors in flash rate and intensity.

• RFI on the control (master/slave) interconnecting wire could cause a light to switch intensity.

• Strong RFI could burn out circuit board components.

Though the circuits reject or bypass RFI, FTCA cannot guarantee complete immunity beforehand. After installa-tion, it may be necessary to add external filters or use other methods to reduce RFI entering the equipment.

Control Line Interference

Electrical interference on the control line can introduce system control problems. This can occur if the line is open, shorted, or not a twisted pair. The condition of all units responding correctly to the master and slave check-out procedures described above, but not when the control wire is connected, indicates a control line problem. Some-times, you can eliminate marginal interference by placing a 1000 ohm resistor between the control line wires at the master unit. Installing a shunt capacitor can also help, but never exceed a value of 0.01 microfarads.

The control line has a ground return to interconnect the unit. Chassis ground is the reference.

Power Phasing

Input power phasing must be consistent, as noted in Sec-tion Wiring on Page 2-2. If even one of the lights is phased differently, none of the lights will switch to low intensity. To isolate an out-of-phase light (or lights), set the system control selector to LOW. Turn off all lights except for the master unit (use interlock switches to accomplish this) and verify that the master flashes at low intensity. Now turn on the remaining lights one at a time and observe the master unit as each one is turned on. If the master unit changes intensity as any of the slave units is turned on, reverse the input power phasing of that slave unit (interchange L1 and L2 at the fuse block). Continue this procedure with all the remaining lights.

Master Unit Checkout P/N 2652318

The master unit contains an internal controller or a con-trol interface panel. Carry out the following steps on the timing and trigger board.

3-2 Revision 1 — 12-11-2003 FTS 400/800-4

1. Temporarily disconnect the input control wire from TB3-6 and the intensity control wire from TB3-7.

2. Apply power to the system and set the control switch to any mode except REMOTE or OFF.

Verify the following response:

a. The LOW LED is not lit.b. The HIGH LED is lit.c. The SYNC LED blinks brightly.

d. The TRIG neon lamp glows.e. The light flashes at high intensity.

3. Place a temporary jumper from TB3-7 to TB3-10 (or the chassis).

Verify the following responses:a. The LOW LED is lit.

b. The HIGH LED is not lit.c. The SYNC LED blinks dimly.d. The TRIG neon lamp glows.

e. The light flashes at LOW intensity.

4. Remove the jumper placed in step 3. Place temporary jumper from TB3-10 (or the chassis) to test point TP8 on the board. Do not confuse TP8 on the board with terminal 8 on the terminal block (please refer to Fig-ure 3-1).

Verify the following responses:a. The HIGH LED is not lit.b. The LOW LED is not lit.

c. The SYNC LED blinks.d. The TRIG neon lamp glows.e. The light flashes at MEDIUM intensity.

f. Remove the jumper between TP8 and TB3-10 (or the chassis).

5. If any LED response in items A to C of steps 2, 3, and 4 above is not exactly as described replace the timing and trigger board. Replace relay K1 or K2 if LED responses are correct but the light flashes at the wrong intensity.

6. Reconnect the intensity control wire to TB3-7, while leaving the system control wire disconnected from TB3-6. Set the control switch to LOW and verify that responses are identical to those in step 3.

7. Set the control switch to MED and verify that responses are identical to those in step 4.

8. Set the control switch to HIGH and verify that responses are identical to those in step 2.

9. If any LED response in steps 6 through 8 is not exactly as described, replace the controller or inter-face panel, or both.

10. Before reconnecting the control wire at TB-6, observe the flash intensity of the other (slave) bea-cons in the system. They should all be flashing at LOW intensity. If not, there is a problem with one of the lighting units or in the system control wire itself.

11. Reconnect the control wire to TB-6. Repeat steps 6 through 8 and verify that all lights flash properly. If any response is not as described, proceed to verify the operation of each slave unit.

Slave Unit Checkout

A slave unit is one that does not contain an internal con-troller or control interface panel. Carry out the following steps on the timing and trigger board of any slave unit. Refer to Figure 3-1.

1. Temporarily disconnect the input control wire from TB3-6 and the intensity control wire from TB3-7.

2. Apply power to the system and at the master unit con-troller, set the control switch to any mode except REMOTE or OFF.

Verify the following responses at the slave unit:

a. The LOW LED is not lit.

b. The HIGH LED is lit.

c. The SYNC LED blinks brightly.

d. The TRIG neon lamp glows.

e. The light flashes at HIGH intensity.

3. Placed a temporary jumper from TB3-10 (or the chas-sis) to test point TP8 on the board. Do not confuse TP8 on the board with Terminal 8 on the terminal block. (Please refer to Figure 3-1).

Verify the following responses:

a. The HIGH LED is not lit.

b. The LOW LED is not lit.

c. The SYNC LED blinks.

d. The TRIG neon lamp flashes.

e. The light flashes at MEDIUM intensity.

FTS 400/800-4 Revision 1 — 12-11-2003 3-3

4. Remove the jumper placed in step 3. Reconnect the intensity control wire removed from TB3-7.

Verify the following responses:a. The LOW LED is lit.b. The HIGH LED is not lit.c. The SYNC LED blinks brightly.d. The TRIG neon lamp glows.e. The light flashes at LOW intensity.

5. If any LED response in items 1 through 4 of steps 2, 3, and 4 above is not exactly as described, replace the timing and trigger board. Replace relay K1 or K2 if LED responses are correct but the light flashes at the wrong intensity.

6. Restore the input control wire to TB3-6.

Master Unit Checkout P/N 2904413

The master unit contains an internal controller or a con-trol interface panel. Carry out the following steps on the timing and trigger board.

1. Temporarily disconnect the input control wire from TB3-6 and the intensity control wire from TB3-7.

2. Apply power to the system and set the control switch to any mode except REMOTE or OFF.

Verify the following response:a. The NITE LED is not lit.b. The DAY LED is lit.c. The TWI LED is not lit.d. The SYNC LED blinks brightly.e. The TRIG neon lamp glows.f. The light flashes at high intensity.

3. Place a temporary jumper from TB3-7 to TB3-10 (or the chassis).

Verify the following responses:a. The NITE LED is lit.b. The DAY LED is not lit.c. The Twi LED is not lit.d. The SYNC LED blinks dimly.e. The TRIG neon lamp glows.f. The light flashes at LOW intensity.

4. Remove the jumper placed in step 3. Place temporary jumper from test point TP1 to test point TP5 on the

board. Do not confuse TP1,5 on the board with termi-nal 1,5 on the terminal block (please refer to Figure 3-2).

Verify the following responses:a. The DAY LED is not lit.b. The NITE LED is not lit.c. The TWI LED is lit.d. The SYNC LED blinks.e. The TRIG neon lamp glows.f. The light flashes at MEDIUM intensity.g. Remove the jumper between TP1 and TP5.

5. If any LED response in items A to C of steps 2, 3, and 4 above is not exactly as described replace the timing and trigger board. Replace relay K1 or K2 if LED responses are correct but the light flashes at the wrong intensity.

6. Reconnect the intensity control wire to TB3-7, while leaving the system control wire disconnected from TB3-6. Set the control switch to LOW and verify that responses are identical to those in step 3.

7. Set the control switch to MED and verify that responses are identical to those in step 4.

8. Set the control switch to HIGH and verify that responses are identical to those in step 2.

9. If any LED response in steps 6 through 8 is not exactly as described, replace the controller or inter-face panel, or both.

10. Before reconnecting the control wire at TB-6, observe the flash intensity of the other (slave) bea-cons in the system. They should all be flashing at LOW intensity. If not, there is a problem with one of the lighting units or in the system control wire itself.

11. Reconnect the control wire to TB-6. Repeat steps 6 through 8 and verify that all lights flash properly. If any response is not as described, proceed to verify the operation of each slave unit.

Slave Unit Checkout P/N 2904413

A slave unit is one that does not contain an internal con-troller or control interface panel. Carry out the following steps on the timing and trigger board of any slave unit. Refer to Figure 3-2.

3-4 Revision 1 — 12-11-2003 FTS 400/800-4

1. Temporarily disconnect the input control wire from TB3-6 and the intensity control wire from TB3-7.

2. Apply power to the system and at the master unit con-troller, set the control switch to any mode except REMOTE or OFF.

Verify the following responses at the slave unit:

a. The NITE LED is not lit.

b. The DAY LED is lit.

c. The TWI LED is not lit.

d. The SYNC LED blinks brightly.

e. The TRIG neon lamp glows.

f. The light flashes at HIGH intensity.

3. Placed a temporary jumper from TP1 to test point TP5 on the board. Do not confuse TP1,5 on the board with Terminal 1,5 on the terminal block. (Please refer to Figure 3-2).

Verify the following responses:

a. The DAY LED is not lit.

b. The NITE LED is not lit.

c. The TWI LED is lit.

d. The SYNC LED blinks.

e. The TRIG neon lamp flashes.

f. The light flashes at MEDIUM intensity.

4. Remove the jumper placed in step 3. Reconnect the intensity control wire removed from TB3-7.

Verify the following responses:

a. The NITE LED is lit.

b. The DAY LED is not lit.

c. The TWI LED is not lit.

d. The SYNC LED blinks brightly.

e. The TRIG neon lamp glows.

f. The light flashes at LOW intensity.

5. If any LED response in items 1 through 4 of steps 2, 3, and 4 above is not exactly as described, replace the timing and trigger board. Replace relay K1 or K2 if LED responses are correct but the light flashes at the wrong intensity.

6. Restore the input control wire to TB3-6.

Troubleshooting

Accurately observe the system’s operating behavior. This often leads directly to the cause of a problem. The diag-nostic procedures in this subsection are divided into the two following categories:

• System-level malfunctions, where all lighting units exhibit the same abnormal behavior

• Symptoms applying to one or more individual light-ing units, but not to all of them

System Level Problems

Table 3-1 identifies symptoms affecting all lighting units in the same way. Use it to determine possible causes.

Individual Light Problems

Use Table 3-2 to identify problems that apply to a particu-lar lighting unit only and to determine possible causes.

The entries listed in Table 3-2 are numbered in the order of their likely occurrence. For example, assume that one of the lights does not flash in any mode (low, medium, or high) and the high voltage (HV) indicators are not lit. However, mode relays operate and circuit board LEDs are lit, which indicates the presence of low voltage (LV). The symptom best describing this condition is No No No No Ok. This symptom has four causes listed in sequence. The HV Rectifier Board is the most likely and the first cause listed. The Power Transformer is the next likely cause and second one listed. In this way, the causes follow in the sequence of their likelihood of occurrence.

All neon lights out on the HV rectifier board indicates the absence of HV. All LED lights out on the timing and trig-ger board indicates the absence of LV.

After determining that the problem’s cause is a specific component, refer to the procedure for testing the compo-nent in Section Component Testing. If the component is faulty, replace it according to the appropriate component replacement procedure in Section Component Removal and Replacement

FTS 400/800-4 Revision 1 — 12-11-2003 3-5

Table 3-1 System-Level Troubleshooting

Flash ConditionsComponent or Condition Notes

High Medium Low

No No No Circuit Breaker CB201/202 or CB301/302 Note 2

No No No Remote Control Fuse F201 or F301Note 1, Note 2

OK Bright Bright High Mode Relay K201 or Low Mode Relay K202 Note 3

Weak Ok Ok High Mode Relay K201 Note 3

Weak Weak Ok Low Mode Relay K202 Note 3

Ok Ok Bright Phase error Note 5

Erratic flashing in all modes Control line not a twisted pair Note 4

Notes:1. Flashes properly when you set the master switch to low, medium, or high but does not flash

when you set the switch to remote.2. 300-series components are associated with an external (remote) control panel; 200-series

components are associated with an internal control panel. A system may have either 200 series or 300 series components, but not both.

3. a.) Check relay contacts for dirt or corrosion.b.) Check relay for normal energizing operation (verify that the relay pulls in).

4. A twist of 6 turns per foot is recommended.5. Refer to Section Power Phasing on Page 3-2

3-6 Revision 1 — 12-11-2003 FTS 400/800-4

.

Table 3-2 Lighting Unit Troubleshooting

Flash ConditionsOther

Conditions Component Or Condition Notes

High Medium Low HV LV

No No No No NoPrimary Fuse F1, F2Interlock Switch S1

No No No No NoPrimary Suppressor Asm. VR1Power Transformer T1Timing and Trigger Board PCB1

Fuses blow when replaced or circuit

breaker trips

No No No No Ok

HV Rectifier Board PCB2Power Transformer T1Main Capacitor Bank C1, C2Flashhead Cable

No No No Ok NoTiming and Trigger Board PCB1Power Transformer T1

No No No Ok Ok

Flashtube FT101HV Rectifier Board PCB2Trigger Transformer T101Power Transformer T1Flashhead CableMain Capacitor Bank C1, C2

No No Ok Ok OkMain Capacitor Bank C1, C2HV Rectifier Board PCB2

Ok Ok No Ok OkLow Mode Capacitor C3HV Rectifier Board PCB2Low Mode Relay K2

Weak Weak Ok Ok OkLow Mode Relay K2Timing and Trigger Board PCB1

Ok Bright Ok Ok Ok HV Rectifier Board PCB2

Skips Ok Ok Ok Ok Tuning Capacitor C4

Skips Skips Skips Ok Ok

Trigger ArcingFlashtube FT101Trigger Transformer T101Coupling Transformer T3

FTS 400/800-4 Revision 1 — 12-11-2003 3-7

81000052

Figure 3-1 PCB1 Timing and Trigger Board Pictorial

3-8 Revision 1 — 12-11-2003 FTS 400/800-4

Figure 3-2 PCB1 Timming and Trigger Board P/N 2904413

FTS 400/800-4 Revision 1 — 12-11-2003 3-9

Component Testing

The following procedures describe how to check most of the major electrical components. Always make resistance measurements with the power turned off. Voltage mea-surements require power to be on; however, perform all preliminary steps such as connecting test leads or circuit jumpers, or disconnecting existing circuit connections, with the power turned off and storage capacitors dis-charged.

Capacitors (C1, C2, C3)

Test capacitors with an ohmmeter capable of measuring one megohm or greater, using the procedure described following.

Resistance measured between the terminals of a fully dis-charged capacitor is initially zero and increases steadily with time if you leave the ohmmeter leads across the ter-minals. Eventually, an open circuit condition occurs. The time it takes for the complete transition from zero to max-imum depends on the total amount of capacitance. A capacitor disconnected from other circuitry is defective if it does not exhibit this behavior. Manually discharge the capacitor before repeating this measurement. This proce-dure may not detect a failure that occurs at high voltage only. Please note that the final measured resistance across C1 is limited to 100K ohms unless you disconnect the safety bleed resistor R1.

Flashtube (FT101)

NOTEProtect yourself — always turn off theinput (primary) power and wait for oneminute for storage capacitors to draintheir charge. Capacitors may be manu-ally discharged by placing a resistance(25 Watts, 10,000 ohms or greater)between their terminals. Then checkbetween the red and blue wires on TB2with a voltmeter for any residual chargebefore touching any circuit element orcomponent.

Do Not Depend on InterlocksNever depend on interlocks alone toremove unsafe voltages. Always checkcircuits with a voltmeter. Under no cir-cumstances remove or alter any safetyinterlock

A visual inspection tells you little about the working con-dition or performance of a flashtube. A darkened enve-lope does not necessarily mean the light output is unacceptable. Do not replace the flashtube until you rule out other causes, such as a lack of discharge potential or triggering pulses.

Relays (K1, K2)A malfunctioning relay may have faulty contacts, a sticky mechanism, or a defective coil. You may determine the first two possibilities by inspection and by manually exer-cising the armature. Perform the following resistance measurement to confirm a defective coil:

1. Remove the PCB1.

2. Measure coil resistance between TB3-7 and the chas-sis to test Low Mode Relay K2.

3. Measure coil resistance between TB3-8 and the chas-sis to test High Mode Relay K1.

The measured coil resistance in either case should be approximately 290 ohms.

High Voltage Rectifier Board(PCB2)

Replace PCB2 with one known to be in good condition.

High Voltage Transformer (T1)

To test this transformer, first remove (PCB1) and (PCB2). Apply power to the unit and measure secondary winding voltages at the terminals indicated.

PERSONNEL HAZARD WARNING

Table 3-3 High Voltage Transformer (T1) Voltages

Terminals Voltage Range

TB4-3 to TB4-11 900-1050 volts AC*

TB3-1 to chassis 100-120 volts AC

TB3-2 to TB3-1 22-26 volts AC

* If this AC voltage is substantially below the specified minimum value, check tuning capacitor C4.

3-10 Revision 1 — 12-11-2003 FTS 400/800-4

Trigger Coupling Transformer (T3)

Visually observe the transformer for damage. Check the transformer for open windings by measuring the primary and secondary windings with an ohmmeter. An open winding indicates infinite ohms on the ohmmeter. A nor-mal winding should indicate less than 200 ohms.

Timing and Trigger Board (PCB1)

Replace this circuit board with one known to be in good condition. You may use temporarily a general purpose spare board, PN 2652318 or PN 2904413. It exercises all functions of the lighting unit but flashing does not occur in the correct sequence. The spare PN 2652318 or PN2904413 board must be programmed as instructed in the Timing and Trigger Board replacement procedure fol-lowing if it is to replace the original circuit board.

NOTEThe PN 2652318 board does not func-tion normally until you program it for oneof the lighting units. Snip out the diodeson the replacement board to matchthose in the board that you are replac-ing. For PN 2904413 see section 5. forthe programming procedure

Bleed Resistor (R1)

The total measured resistance of the bleed circuit should be 85,000 ohms.

Interlock Switch (S1)

Try adjusting the switch bracket. The switch should clearly read zero ohms when it is closed and infinite ohms when it is open.

Component Removal and Replacement

This section contains instructions for removal and replacement of most major replaceable components. Refer to Section 4 for parts lists and locations, and com-ponent location diagrams for assembly and disassembly. Refer to Section 2 for installation and internal wiring. Figure 2-11 shows a wiring diagram for the flashheads. Internal wiring for the power converters is shown in Fig-ure 2-12.

High Voltage Transformer (T1)

Removal1. Disconnect wires leading to the transformer

2. Remove four screws holding the transformer to the rear of the chassis and remove the transformer from the chassis.

ReplacementReverse the removal procedure. Verify that wiring agrees with Figure 2-12.

Trigger Coupling Transformer (T3)

Removal1. Disconnect the Faston connectors. Note the wire

directions at the top of the primary and secondary coils.

2. Remove the two 4-40 x 2" phillips head screws hold-ing the transformer assembly to the bracket.

3. Remove the transformer.

Replacement1. Reinstall the windings in the directions noted in Step

1 of Removal. Ensure that the wires have the same orientation.

2. Reattach the electrical wires. Verify that wiring agrees with Figure 2-12.

Timing and Trigger Board (PCB1)

Removal1. Loosen, but do not remove, all eleven screws holding

the circuit board to TB3.

2. Loosen, but do not remove, the screws at the top that hold the board to the front of the chassis and lift the board from TB3.

Replacement1. If you are replacing the PCB1 with a spare (PN

2652318 or PN 2904413), you must program the spare to initiate flashing in the proper sequence. For PN 2652318 program it by removing diodes from PCB1 for a specific lighting position by snipping out the appropriate diodes to match exactly those that are removed in the board you are replacing. Do not pro-gram the spare board until you are certain that you

FTS 400/800-4 Revision 1 — 12-11-2003 3-11

want to use it in a particular position. For PN 2904413 see section 5.

2. Perform steps 1 and 2 of the Removal procedure in the reverse order.

HV Rectifier Board (PCB2)

Removal1. Loosen, but do not remove, all eleven screws holding

the circuit board to TB4.2. Loosen, but do not remove, the screws at the top that

hold the board to the front of the chassis and lift the board from TB4.

ReplacementReverse the Removal procedure.

Capacitors

Removal1. Disconnect the wires leading to the capacitors.2. Remove the hold-down screws. Lift capacitors from

their receiving holes and away from the chassis.

Replacement1. Insert capacitors into their respective receiving holes.

2. Replace hold-down screws to secure capacitors to the chassis.

3. Reconnect wires to capacitors and verify that wiring is an accordance with Figure 2-12.

Wires must be replaced exactly as removed. In some instances, a quick-connect wire terminal does not seat properly if it is not placed on the terminal cluster exactly as it was before removal. Sometimes the insu-lation on the wire terminal interferes with the insula-tion surrounding the terminal cluster on the capacitor.

3-12 Revision 1 — 12-11-2003 FTS 400/800-4

Section 4 — Replaceable & Spare Parts

Customer Service

Customer Service: 1-800-821-5825Telephone: (615) 261-2000Facsimile: (615) 261-2600Shipping Address:

Flash Technology Corporation of America332 Nichol Mill LaneFranklin, TN, 37067

Ordering Parts

To order spare or replacement parts, contact FTCA cus-tomer service at 1-800-821-5825.

Power Converter Parts

Table 4-1 lists the major replaceable parts for the power converter.

Internal Controller Parts

Table 4-2 lists the major replaceable parts for the FTC 415 Internal Controller.

Series Controller Parts

Table 4-3 lists the major replaceable parts for the FTC 435 Series Controller.

Flashhead Parts

Table 4-4 lists the major replaceable parts for the FH 400 Flashhead and the FH 800 Flashhead.

Returning Equipment

Before returning equipment, call Customer Service at 1-800-821-5825 for a Return Material Authorization (RMA) number.

Repackaging

Return equipment in a container that provides maximum protection during shipping and handling. If the original cartons and packaging material are no longer available, package the units as follows:

Ship and package the power converter in an upright posi-tion; that is, with the feet downward. Pad the unit so that the feet cannot penetrate the box during shipment. Box each unit separately using a double thickness cardboard container and adequate padding. Do not drop. Use appro-priate warning labels on the outside of the container.

If you send the flashhead separately, package it in any reasonable, strong, corrugated cardboard box with enough firm padding surrounding the flashhead to pre-vent damage.

FTS 400/800-4 Revision 1 — 12-11-2003 4-1

Table 4-1 Power Converter Major Replaceable Parts

Unit DescriptionPart

NumberQuantity

All Enclosure 3727901 1

All Spacer, Ceramic 5900842 2

All R1, Resistor, 35K, Bleed 6900541 1

All R2, Resistor, 50K, Bleed 6900542 1

All T1, Transformer, Power:120VAC

230/240VAC 60hz230/240VAC 50hz

884120188412028842901

111

All K1/K2, Relay, Mode 8900494† 2

All L2, Choke, Flash 4175200 1

All T3, Transformer, Trigger Coupling 8336710 1

All TB2 Terminal Strip, 8-position 8721008 1

All PCB2, HV Rectifier Board 2458002† 1

All R4, Resistor 8435212 1

All Terminal Strip, 11-position 8721011 2

All PCB1, Timing and Trigger Board, unprogrammedOR

2652318†

2904413†11

All F1/F2, Fuse, Power 4900342 2

All VR1, Suppressor 6901081 1

All VR2, Suppressor 6901079 1

All TB1, Terminal Strip, 6-position 8721006 1

All R3, Resistor, Buffer 8435211 1

All Interlock Switch 4901220 1

PC800 C1, 20 mfd. capacitor 6731401 1

PC800 C2, 70 mfd. capacitor 6720401 1

PC800 C4, 3 mfd. capacitor 6577903 1

PC800 C5, C 6, 15 mfd. capacitor 6731301 2

PC800 C7, 5 mfd. capacitor 6731101 1

PC400 C1, 20 mfd. capacitor 6731401 1

PC400 C2, 40 mfd. capacitor 6386503 1

PC400 C4, 3 mfd. capacitor 6577903 1

PC400 C5, C6 15 mfd. capacitor 6731301 2

PC400 C7, 8 mfd. capacitor 3731201 1

Optional ETM Elapsed Time Meter 1749201 1

Optional K3 Flash Monitor Module 1851001 1

† Recommended as a spare part. NOTE: Program the spare board (PN 2652318) by removing the diodes in the spare to match exactly those that are removed in the PCB1 board that you are replacing. See section 5. for pro-gramming PN 2904413.

4-2 Revision 1 — 12-11-2003 FTS 400/800-4

81000041

Figure 4-1 PC 400 and PC 800 Power Converter Component Locations

PCB2F2

1 2

FRONT VIEW

9

TB33 4 5 6 7 8 10 11 1 5432

TB4876 11109

F1

T3

K2

PCB1

REAR VIEW

L2 K1 T1

END VIEW

61 2 3 4 5TB2

7 8

R1

ELAPSED TIME METER (OPTIONAL)

G2

G1

TB1

6

4

5

2

1

3

ETM

R4

R3

VR2

S1

3-7403-01S

C2C1

C5 C6

C4

C7R2

FTS 400/800-4 Revision 1 — 12-11-2003 4-3

81000044

Figure 4-2 FTC 415 Controller Component Locations

Table 4-2 FTC 415 Controller PartsDescription Part Number Quantity

Relay: K203< Power120VAC

230/240VAC8900493†

4900495†11

Relay: K201 & K202, Mode120VAC

230/240VAC4900501†

4901762†22

S201 Rotary Switch 4900893 1

F201 Fuse 4900342 1

Fuse Holder 4900377 1

TB201 Terminal Strip, 11-position 8721011 1

Suppressor:120VAC

230/240VAC69010796901081

11

Resistor 8435210 1

CB1 Circuit Breaker 4900120 1† Recommended as a spare part.

REMOTE

RELAY

TB

201

CB1

OFF OFF

POWER21 3 4 5 6 CTRL HI

POWER RELAYK203

MED

K202

RELAY

MED

HIGH

3-7355-01G

LOWFTC 415

REMOTE

FUSELOM N

MODE

OFF

F201HIGH

K201

S201

4-4 Revision 1 — 12-11-2003 FTS 400/800-4

81000045

Figure 4-3 FTC 435 Series Controller Component Locations

Table 4-3 FTC 435 Controller Parts

Description Part Number Quantity

PCB, Current Sense Board 2760702 1

PCB, Relay Board 2767902 1

Enclosure 3714800 1

Transformer 4734500 1

Switch, Rotary 4900892 1

Terminal Strip, TB1, 3-position 4902157 1

Terminal Strip, TB2, 4-position 4902073 1

Terminal Strip, 11-position 8721011 1

HIGH

MED

LOW

AUTO

INTENSITY CONTROL

PCB CURRENT SENSE BOARD

PCB RELAY BOARD ENCLOSURE

ROTARY SWITCH

TERMINAL STRIP, 11-POSITION

TRANSFORMER

TB1 TB2

FTS 400/800-4 Revision 1 — 12-11-2003 4-5

.

Table 4-4 FH 400 and FH 800 Flashhead Major Replaceable Parts

Flashhead Description Part No. Quantity

FH 400 Lens 8743701 1

FH 400 Trigger Transformer 8288201 1

FH 400 Clamp, Lens 3893201 3

FH 400 Spacer, Ceramic 5900844 4

FH 400 RC Network RC101 1403411 1

FH 400 Flashtube FT 101 8384329† 1

FH 400 Terminal Screw Lug 3379102 3

FH 400 Spacer, Ceramic 5900842 4

FH 800 Flashtube FT101 8901701† 1

FH 800 RC Network RC101 1403411 1

FH 800 Trigger Transformer 8288201 1

FH 800 Post, Ceramic 5900842 4

FH 800 Retaining Bezel 3735202 3

† Recommended as a spare part.

4-6 Revision 1 — 12-11-2003 FTS 400/800-4

81000046

Figure 4-4 FH 400 Flashhead Component Locations

LENS

TRIGGER

FLASHTUBE

RC NETWORK

TRANSFORMER

CERAMICPOSTS

WH

T

BLK

BLU

RE

D

PU

R

RED DOT

WHITE TRIGGER

WIRE FROMTRIGGERTRANSFORMER

REDDOT

SECONDARY

SMALL BLUESECONDARY WIREFROM TRIGGERTRANSFORMER

REDBLUEBLACKWHITEPURPLE AND GROUND

FLASH HEADCABLEWIRES

RC NETWORK

REDCONNECTINGWIRE

BLUECONNECTINGWIRE

CERAMIC POSTSFASTONS

WHITE TRIGGERSECONDARY WIRE

BLUEWIRESWITHFASTONS

BLUE SECONDARYWIRE

BLUEWIRES

CONNECTEDTO FASTONS

ON PRIMARY COILOF TRANSFORMER

LENS CLAMP (3 PIECES)

FTS 400/800-4 Revision 1 — 12-11-2003 4-7

81000047

Figure 4-5 FH 800 Flashhead Component Locations

BEZEL

FLASHTUBE

RC NETWORK

TRIGGERTRANSFORMER

CERAMIC POSTS

RC NETWORK

WHITEWIRE TO

FLASHTUBE

RED WIRE TO FLASHTUBEBLUE WIRE TO FLASHTUBE

GROUNDANDMOUNTINGNUT

MOUNTINGNUT

MOUNTINGNUT BLUE

SECONDARYWIRE

BLUEFASTONS

BLUEWIRES

PRIMARY

SECONDARY

PURPLE WIRE

BLUEWIRE

BLACK WIRE

GROUND WIREBLUE WIRE

RED WIREWHITE WIRE

STUD

STUD HOLE

RAISED ARROWON FLASHTUBEFACE

NOTE:1. WHEN INSTALLING THE FLASHTUBE IN THE HOUSING, ALIGN THE RAISED ARROW ON THE FLASHTUBE FACE WITH THE STUD ON THE RIM OF THE HOUSING.

RED

WHITE

BLUE

REAR VIEW OFFLASHTUBE -

CONNECTIONS

4-8 Revision 1 — 12-11-2003 FTS 400/800-4

Section 5 — Programming T&T Board P/N 2904413

Connecting the Handheld

Table 5-1 shows the connector pin assignments for the handheld. The receive and transmit directions shown in the table are with respect to the handheld. The DB9 con-nector is located at the top of the handheld programmer.

A 9-pin RS-232 cable is used to connect the handheld to the 9044-01 controller board at connector J2 (9 pin Male connector). Power and ground is provided by this connec-tor.

The same connector J2 on the 9044-01 is also used to connect a computer serial port for the enhanced user interface. This interface is used to set parameters, run pro-duction and vendor tests and display general operating information.

Figure 5-1 FIGURE 5-1 Handheld Program-mer

Using the Programmer

The programmer has a four line LCD display and 24 keys as shown in fig. 5.1.

The following is a general discussion of how the pro-grammer works. See Parameters under the SETUP sec-tion below for more details.

In the discussions to follow the 4 line LCD display will be represented as shown:

Table 5-1 Pin Assignments

DB9 Female EIA-232 Function

3 Receive +receive

6 No connection -receive

2 Transmit +transmit

1 No connection -transmit

9 Power

5 Ground

FTS 400/800-4 Revision 1— 12-11-2003 5-1

L1: **********

L2: **********

L3: **********

L4: **********

All the messages displayed on the LCD will be in capital letters.

The display does not show the L1: etc. this is used to rep-resent line 1, 2, 3 and 4 on the LCD.

Once the handheld programmer is connected to the 9044-01 and power is applied the 9044-01 will automati-cally recognize that the terminal is connected to it and will display the sign on message . Only terminals pro-vided by Flash Technology will work with the 9044-01.

The general format of the sign on message is:

L1: FLASH TECHNOLOGY

L2: BOARD 5978

L3: (Blank or further information)

L4: ENTER TO CONTINUE

Once enter is pressed the first menu is displayed as fol-lows:

L1: PRESS A FUNC KEY

L2: F1. SETUP F2. INFO

L3: F3. SHORTTEST

L4: F4. MODE CHANGE

To continue further a function key must be pressed. The function keys are on the top row of the terminal. See fig. 5.1.

F1: Enters the setup menus, used to configure the 9044-01.

F2: Enters the information menu, used to show a limited amount of useful operating info.

F3: Causes the 9044-01 to perform the short test.

F4: Enters the mode change menu, used to manually change the operating mode (HIGH, MED, and LOW). Note: For PN 2904413 DAY equals HIGH, TWI equals MED and NITE equals LOW intensity

Note: The handheld terminal will return to the sign on message from any other menu if no key is pressed within two minutes. The 9044-01 does this to take the serial port out of the handheld terminal mode if the terminal has been removed to allow the serial port to be used for the enhanced user interface. This means that if you remove the handheld terminal and connect a computer to use the enhanced interface you must wait at most two minutes before pressing any key on the computer. You can cycle the power to the 9044-01 for faster access to the computer interface.

SETUP

The setup menu has the following format:

L1: SETUP

L2: 0-1-1

L3:

L4: OK NEXT BACK EXIT

The first line displays the current menu. The second line displays the current setup. The numbers correspond to the selected parameters. The third line is blank. The fourth line displays what functions the keys F1 thru F4 will per-form if pressed; the words are spaced to be over the corre-sponding function key. So, to move to the next menu you would press F2 (NEXT).

F1: OK- is used to enter data.

F2: NEXT- moves to the next item.

F3: BACK- moves to the previous item.

F4: EXIT- exits the setup menu.

5-2 Revision 1 — 12-11-2003 FTS 400/800-4

Parameters

Pressing the NEXT or BACK function key from the SETUP menu takes you to the parameters. The general format is:

L1: SETUP

L2: SYSTEM

L3: 0- Bec. 1- Air. 2- Hel

L4: OK NEXT BACK EXIT

The currently selected option will have the cursor under it. For example:

0-Bec 1-Air 2-Hel shows that the currently selected option for the parameter is zero (0) which in this case means Omni Beacon.

If the board your are configuring is not in the Airport mode press 1 and press F1 (OK). **Note: Even if your board is configured for Airport mode you will need to press 1 and F1 to change the light number.**

The display will change to:

L1: SETUP

L2: AIRPORT # 1

L3: Enter Light #

L4: OK NEXT BACK EXIT

Press the number keys to select the light number you wish this board to be and then press F1 (OK). The Airport number displayed will change. When you are done press NEXT or BACK.

To change the Flash rate press NEXT until the LCD shows: NOTE: Valid flash rates are 60fpm for 400 series lights and 120 fpm for 800 series lights.

L1: SETUP

L2: FPM 1-60 2-30

L3: 3-20 4-100 5-120

L4: OK NEXT BACK EXIT

Then press 1 for the 400 series or 5 for the 800 series and press F1 (OK)

Flicks default to single and generally do not need to be changed. To change the flicks press NEXT until the LCD shows:

L1: SETUP

L2: FLICKS

L3: 0-Single 1-Double

L4: OK NEXT BACK EXIT

Then press 0 or 1 and press F1 (OK) to change it. Note that 0-Single is the default and the standard.

INFO

The info menu has the following format:

L1: INFO

L2: BOARD 5978

L3:

L4: NEXT BACK EXIT

This menu is used to show a limited amount of informa-tion about the current 9044-01 operation and configura-tion.

The first line displays the current menu. The second and third lines display board information. The fourth line dis-plays what functions the keys F2 thru F4 will perform if pressed; the words are spaced to be over the correspond-ing function key. So, to move to the next item you would press F2 (NEXT).

F2: NEXT- moves to the next item.

F3: BACK- moves to the previous item.

F4: EXIT- exits the setup menu.

FTS 400/800-4 Revision 1— 12-11-2003 5-3

Items like energy, trigger voltage, flash rate and operating mode are displayed.

MODE CHANGE

The mode change menu has the following format:

L1: MODE CONTROL

L2: CURRENT DAY/HIGH

L3:

L4: HIGH MED LOW EXIT

F1: HIGH- Changes the intensity to DAY/HIGH.

F2: MED- Changes the intensity to TWI/MED.

F3: LOW- Changes the intensity to NITE/LOW.

F4: EXIT- exits the mode change menu and returns the mode to automatic.

This menu item is used to manually change the operating modes and functions just like the test jumpers on the board.

5-4 Revision 1 — 12-11-2003 FTS 400/800-4

INDEX

AAccess 2-1

FH 400 flashhead 2-1FH 800 flashhead 2-1power converter 2-1

ALSfigure

basic configuration 2-5FTS 400

basic description 1-1FTS 800

basic description 1-1light alignment 1-1

BBleed resistor testing 3-11

CCapacitor

removal 3-12testing 3-10

Checklistinstallation 2-2

Checkoutmaster unit 3-2slave unit 3-3, 3-4

CI 425 control interfacepart location figure 4-4

Comounted unitmounting and outline figure

PC 400 2-10PC 800 2-11

Componentremoval and replacement 3-11testing 3-10

Configurationfigure

basicALS 2-5REIL 2-4

Control line interference 3-2Control signal evaluation 3-1Controls

figureFTC 435 series controller 1-4FTC 435 system controller

current sense board 1-4Controls and indicators 1-2

figureFTC 415 system controller 1-3

tableFTC 415 system controller 1-3

Customer service 4-1

DDiagnostic testing 3-1

EElapsed time meter 1-2Equipment

returning 4-1storage 3-1

FFH 400 flashhead

access 2-1basic description 1-1figure

mounting and outline 2-7part location figure 4-7parts table 4-6

FH 800 flashheadaccess 2-1basic description 1-1figure

mounting and outline 2-8part location 4-8

parts table 4-6Flash monitor 1-2Flashhead

figureinternal wiring 2-14mounting and outline

FH 400 2-7FH 800 2-8

mounting check 2-3wiring check 2-3

Flashtubetesting 3-10

FTC 415figure

system controllerinternal wiring 2-16

FTC 415 system controllercontrols and indicators figure 1-3

FTS 400/800-4 Revision 1—12-11-2003 I-1

controls and indicators table 1-3figure

part location 4-4parts table 4-4

FTC 435figure

system controllerinternal wiring 2-17

FTC 435 system controllerbasic description 1-2figure

controls 1-4current sense board 1-4mounting and outline 2-9

part location figure 4-5parts table 4-5setup 1-4

FTS 400basic description 1-1

FTS 800basic description 1-1

GGeneral information 1-1

HHigh voltage, See HVHV

rectifier boardremoval 3-12testing 3-10

transformerremoval 3-11testing 3-10

IIndividual light problems 3-5Installation 2-1

checklist 2-2figure

typical wiringFTC 435 series controller 2-13FTS 410 or FTS 810

with internal controller 2-12typical wiring 2-2

Interferencecontrol line 3-2radio frequency 3-2

Interlock

switch testing 3-11

LLight problems

individual 3-5Location

figureCI 425 control interface parts 4-4FH 400 flashhead parts 4-7FH 800 flashhead parts 4-8FTC 415 system controller parts 4-4FTC 435 system controller parts 4-5power converter parts 4-3

MMaintenance

preventive 3-1Master unit checkout 3-2Meter

elapsed time 1-2Mounting 2-1

flashhead check 2-3power converter check 2-3

Mounting and outlinecomounted unit figure

PC 400 2-10PC 800 2-11

figureflashhead

FH 400 2-7FH 800 2-8

FTC 435 system controller 2-9power converter 2-6

OOperation

basic 1-2Ordering parts 4-1

PParts 4-1

ordering 4-1table

FH 400 flashhead 4-6FH 800 flashhead 4-6FTC 415 system controller 4-4FTC 435 system controller 4-5power converter 4-2

PCB1 timing and trigger boardfigure 3-8

I-2 Revision 1— 12-11-2003 FTS 400/800-4

Phasepower 3-2

Power converteraccess 2-1figure

internal wiring 2-15mounting and outline 2-6part location 4-3

mounting check 2-3parts table 4-2

Power phasing 3-2Preventive maintenance 3-1Problems

individual light 3-5system level 3-5

RRadio frequency interference, See RFIREIL

figurebasic configuration 2-4

light alignment 1-1Relay

testing 3-10Removal

capacitor 3-12component 3-11components 3-11HV rectifier board 3-12HV transformer 3-11timing and trigger board 3-11trigger coupling transformer 3-11

Repackaging 4-1Replacement

component 3-11Returning equipment 4-1RFI 3-2

SSafety 3-1, 5-1Setup

FTC 435 system controller 1-4Slave unit checkout 3-3, 3-4Specifications 1-1Storage

equipment 3-1System

operation

basic 1-2System-level problems 3-5

TTesting

bleed resistor 3-11capacitors 3-10components 3-10diagnostic 3-1flashtubes 3-10HV rectifier board 3-10HV transformer 3-10interlock switch 3-11relays 3-10timing and trigger board 3-11trigger coupling transformer 3-11

Timing and trigger boardfigure 3-8removal 3-11testing 3-11

Tools 2-1Transformer

removalHV 3-11trigger coupling 3-11

Trigger coupling transformerremoval 3-11testing 3-11

Troubleshooting 3-5table

individual light 3-7system-level 3-6

UUnpacking 2-1

WWiring

checkflashhead 2-3power converter 2-3

figureinternal

flashhead 2-14FTC 415 system controller 2-16FTC 435 system controller 2-17power converter 2-15

typical installationFTC 435 series controller 2-13

FTS 400/800-4 Revision 1—12-11-2003 I-3

FTS 410 or FTS 810 with internalcontroller 2-12

I-4 Revision 1— 12-11-2003 FTS 400/800-4